Electrical connector

Abstract: An electrical connector (1), comprises; an insulating housing (2), a contact receiving cavity (3) in the housing (2), and an electrical contact (4) in a first cavity portion (5) of the cavity (3) for connection to a mating electrical contact (7) of another, mating electrical connector (8). A contact portion (15) of the contact (4) extends along the cavity (3), a tip (17) of the contact portion (15) is received in a first channel (24) of the cavity (3), and the contact portion (15) projects into a second cavity portion (6) of the cavity (3), the second cavity portion (6) being open along two intersecting sides (9,10) of the housing (2) for connection to the mating electrical contact (7) of the other mating electrical connector (8).

Description: The present invention relates to an electrical connector for a package that is accessible along two intersecting sides for receiving a mating electrical contact of another, mating electrical connector. For example, an electrical connector for a package is disclosed in EP-A-0 617 486 wherein the package is suitable for containing an electrical device in the form of battery cells. The battery cells are merely exemplary of electrical devices of many varieties and kinds that could be contained int he package, and that utilize terminals protected by the package. An electrical connector for a package includes one or more electrical contacts that are accessible through an end and a side of an insulating package, with the package protecting the contacts. The package is adaptable for containing various kinds of electrical devices that utilize the contacts for electrical connection to another, mating electrical connector, such as a header mounted to a circuit board. According to GB-A-2 280 995 an electrical connector for a package is adapted for upside down, or top side up, mating connection with another, mating electrical connector. The documents EP-A-0 617 486 and GB-A-2 280 995 have both been published after the priority date of the present invention. US-A-4 457 570 discloses a modular jack for directly coupling a printed circuit board and a standard, miniature, telephone-style modular plug. The jack housing includes a cavity open along two intersecting sides at the front portion thereof for receiving the modular plug. It includes conductors having spring contact portions that extend diagonally forwardly of the cavity from the rear part of the cavity to be engaged with the similarly spaced contact terminals of the modular plug. The forward ends of the contact portions are received in channels in the cavity whilst the other ends of the jack's conductors extend normally from the rear wall of the housing to fit within correspondingly spaced apertures in the printed circuit board. EP-A2-0 353 421 describes an edge design for a printed circuit board having spring biassed contact members mounted in a first portion of a contact receiving cavity and having a contact portion extending into a second portion of the cavity for engaging contact tabs of a circuit board inserted into the cavity. The tips of the contact portions are engaged in a channel extending along the front of the cavity. The present invention consists in an electrical connector comprising an insulating housing having one or more contact receiving cavities, an electrical contact disposed in the or each cavity for electrical connection to a mating electrical contact, the or each cavity being open along two intersecting sides of the housing so as to receive the mating electrical contact in the cavity and also having an opening along a third side through which the contact is inserted into the cavity upon assembly, the or each contact having a cantilever contact portion which extends diagonally and forwardly within the cavity towards the two open intersecting sides and which has a tip received in a channel in the cavity, wherein the or each cavity comprises first and second cavity portions, the associated contact is disposed in the first cavity portion with its contact portion extending into the second cavity portion, and the channel receiving the tip of the contact portion extends forwardly in the first cavity portion from the opening in the third side. With the invention, the tip of the or each contact portion is tucked inside a channel in the insulating housing that covers the tip to protect the tip from damage. This feature provides protection for the contact portion to such an extent, that the entirety of the electrical contact can be manufactured in a small and inherently fragile size. For example, in one, alternative embodiment, the electrical contact comprises a thin blade, with the contact portion projecting outwardly of a thickness plane of the blade to engage a mating electrical contact of another, mating electrical connector, and with a tip of the contact portion being received in a channel of the insulating housing. According to the invention, an electrical connector comprises, an insulating housing, a cavity in the housing having a contact receiving first cavity portion and a second cavity portion for receiving a mating electrical contact of another, mating electrical connector, an electrical contact in the first cavity portion, a contact portion on the electrical contact projecting along the second cavity portion for connection to a mating electrical contact of another mating electrical connector received in the second cavity portion, and a tip of the contact portion being received behind a shoulder in a channel of the first cavity portion. An embodiment of the present invention will now be described by way of example with reference to the accompanying drawings, in which: FIGURE 1 is an isometric view of a connector and another, mating connector; FIGURE 2 is an isometric view of a rear side of the mating connector shown in Figure 1; FIGURE 3 is an isometric view of an electrical contact of the mating connector shown in Figure 1; FIGURE 4 an end view of the connector shown in Figure 1; FIGURE 5 is a section view taken along the line 5-5 of Figure 4; FIGURE 6 is a front side view of the connector shown in Figure 1; FIGURE 7 is a fragmentary rear side view of the connector shown in Figure 1; FIGURE 8 is an isometric view of an electrical contact of the connector shown in Figure 1; FIGURE 9 is a fragmentary isometric view of the connector shown in Figure 7, shown partially broken away as depicted along the line 9-9 of Figure 7; FIGURE 10 is a view similar to Figure 9, illustrating an installed contact according to Figure 8; and FIGURE 11 is a rear side view of the connector shown in Figure 6, partially broken away to illustrate further details. With reference to Figures 1, 6, 7 and 9-11, an electrical connector 1 comprises, an insulating housing 2 , at least one cavity 3 in the housing 2, and an electrical contact 4 in each cavity 3. Each cavity 3 comprises, a first cavity portion 5 for receiving the contact 4, and a second cavity portion 6 for receiving another, mating contact 7 , Figure 1, of a mating connector 8 . The second cavity portion 6 communicates with the first cavity portion 5, and is open along a bottom side 9 and a front side 10 , comprising, two intersecting sides of the housing 2, for receiving the mating contact 7. For example, the housing 2 is adapted to be connected to a circuit board of an electrical device, not shown. Further, for example, each electrical contact 4 comprises an electrical terminal for such an electrical device. With reference to Figure 8, one said contact 4 will be described. Said contact 4 is of unitary construction, stamped and formed from a strip or blank of thin metal. The contact 4 has a thickness plane defined by the blank. In one embodiment, the contact 4 comprises, in part, a thin blade 11 extending in the plane of thickness. Barbs 12 project from respective top and bottom edges 13, 14 of the blade 11. A contact portion 15 extends forwardly and diagonally from a front edge of the blade 11, and provides a cantilever, resilient spring. The diagonal length provides a longer cantilever spring than would a length extending straight forward. The contact portion 14 is bowed along its length, and has an obversely curved contact surface 16 adjacent to a reversely bent tip 17 . At a rear of the contact 4, on the blade 11, is an elbow shaped, electrical terminal 18 pointing downward. The terminal 17 is bent outwardly from the plane of thickness of the blade 11. A foot 19 of the terminal 18 is bent to provide a surface mount terminal that is adapted to mount flatly to a surface of a circuit board by a solder joint, not shown. Alternatively, the tip 19 can remain unbent to provide a post, not shown, for mounting in an aperture of a circuit board, not shown. The housing 2 of the connector 1 will now be described with reference to Figures 6-11. The housing 2 is shown inverted in Figures 6, 7 and 9-11. Projecting feet 20 are on the bottom side 9 of the housing 2 to elevate the bottom side 9 from a surface of a circuit board, not shown. Projecting posts 21 on the bottom side 9 are adapted to extend through openings in a circuit board, not shown. Metal board locks 22 are mounted onto the housing 2 and project from the bottom side 9 of the housing 2. The first cavity portion 5 of each cavity 3 projects forwardly from a rear side 23 , Figures 7, 9 and 10, of the housing 2. With reference to Figures 7, 9, 10 and 11, along top and bottom edges of the first cavity portion 5, a first channel 24 and a second channel 25 are aligned with each other. The first channel 24 has a stepped width defining a groove 26 and a shoulder 27 . Both channels 24, 25 are slightly wider than the thickness plane of the contact 4, to receive edgewise the top and bottom edges 13, 14 of the blade 11. The opposite edges 13, 14 of the blade 11 are moved forwardly along the respective channels 24, 25 until the elbow shaped, electrical terminal 18 registers in a recess 28 , Figures 9 and 10, in the rear side 23 and the bottom side 9 of the housing 2. The barbs 12 on the blade 11 imbed in bottoms of respective channels 24, 25 to resist relative movement of the blade 11 and the housing 2. With reference to Figures 9 and 10, the width of the first channel 24 is stepped to receive both, the width of the blade 11, and the tip 17 of the contact portion 15. Both the blade 11 and the tip 17 of the contact portion 15 are moved forwardly along the first channel 24. The tip 17 of the contact portion 15 remains within the first channel 24 behind the shoulder 27, and is protected from being struck by the mating contact 7 to be received in the second cavity portion 6. With reference to Figure 10, the contact portion 15 extends forwardly of the blade 11 to occupy a front portion of the cavity 3 that is unoccupied by the blade 11. The contact portion 15 extends diagonally forward with respect to the blade 11 and diagonally forward with respect to the cavity 3. Thereby, the spring length, along a diagonal direction, is desirably longer than a spring length that would extend straight forward. The contact portion 15 is bowed to project laterally outward from a plane of thickness of the blade 11 and to project, at least partially, into the second cavity portion 6. With reference to Figure 3, each mating contact 7 will be described. Each mating contact 7 is of unitary construction, stamped and formed from a metal strip. Initially, the mating contact 7 is joined with a carrier strip 28 , shown with a pilot hole 29 . Subsequently the mating contact 7 is separated from the carrier strip 28 along the dotted line 30 . Each mating contact 7 comprises a thin blade, with a width defined by a plane of thickness of the blade. An electrical terminal 31 extends from a lower edge 32 of the blade for connection to a circuit board, not shown. For example, the terminal 31 in the form of an elongated post is adapted for mounting in an aperture of circuit board. The terminal 31 can have other forms, for example, a form adapted as a known, surface mount terminal, not shown, that is adapted to mount to a surface of a circuit board by a solder joint, not shown. Each mating contact 7 is constructed with a front projecting finger 33 along the lower edge 32, and a rear 34 from which a pair of locking flanges 35 extend rearwardly, the flanges 35 being bent to project diagonally outward from the thickness plane. With reference to Figures 1, 2 4 and 5, the mating connector 8 further comprises, a unitary, one piece, insulating housing block 36 , which comprises, a base 37 for mounting on another circuit board, not shown, a side wall 38 extending from the base 37, and projecting end barriers 39 extending outward with respect to the side wall 38, and extending upward with respect to the base 37. The base 37 is mounted to a circuit board by fasteners, for example, posts 40 depending from the base 37. At least one cavity 41 in the side wall 38 is adapted to receive a respective, mating contact 7 that is inserted into the cavity 41 from a rear of the housing block 36. Each cavity 41 is slotted with a width only slightly wider than the thickness plane of the mating contact 7, so as to receive and to interfit with the edgewise width of the mating contact 7. Each cavity 41 extends from the rear of the housing block 36 and forwardly through the sidewall 38, and forwardly along the base 37. The terminal 31 of such mating contact 7 projects from the cavity 41 through a bottom of the base 37 for connection to a circuit board, not shown. For example, the terminal 31 is an elongated post adapted for mounting in an aperture of a circuit board. The terminal 31 is moved forwardly along the cavity 41 together with the remainder of the mating contact 7 until a front wall 42 of the cavity 41 resists further forward movement of the terminal 31 relative to the base 37. A front of the cavity 41 extends under the front wall 42 and beneath a ledge 43 , Figures 1 and 5, along a front of the base 37. The finger 33 of the contact 7 is moved along the cavity 41 together with the remainder of the contact 7, until the finger 41 registers under the ledge 43 to resist upward movement of the contact 7 relative to the base 37. Each of the locking flanges 35, Figure 5, must deflect resiliently into the thickness plane of the mating contact 7 to enter into the cavity 41. After entering the cavity 41, each of the locking flanges 35 springs resiliently outward of the thickness plane to register in a recess 44 , Figure 5, that is a portion of the cavity 41. The locking flanges 35 face a front facing wall 45 in the recess 44 to resist rearward movement of the mating contact 7 relative to the base 37. Each contact 7 extends from the base 37 of the housing block 36 toward the open top of the housing block 36, and toward the open side of the housing block 36. Each contact 7 is accessible through both the open top and the open side of the housing block 36 for connection to a contact 4 of the connector 1. The end barriers 39 are at opposite ends of a row comprised of each mating contact 7. The barriers 39 are at least slightly taller than each mating contact 7 to protect the mating contact 7 from being struck accidentally. The sizes and spacing of the barriers 39 are adapted for matching with the sizes and spacing of recesses 46 , Figures 1 and 11, in the side 10 of the housing 2 of the connector 1. The barriers 39 have different widths for coupling by insertion into the recesses 46 of matching, different widths, that are in the front side 10 of the housing 2. The barriers 39 would be unable to couple with recesses 39 of incompatibly different sizes and spacing comprising, for example, those on a different, incompatible housing 1. Further, the recesses 46 of different widths may vary to distinguish different connectors 1. The connector 1 can couple or uncouple from the mating connector by relative motion involving movement of the front side 10 into the open side of the mating connector 8, or by relative motion involving movement of the bottom side 9 into the open top of the mating connector 8. Pivotal motion can accompany the described relative motion of the connector 1, even while the respective contacts 4, 7 of the connectors 1, 8 are engaged.

Claims: An electrical connector (2) comprising an insulating housing (2) having one or more contact receiving cavities (3), an electrical contact (4) disposed in the or each cavity (3) for electrical connection to a mating electrical contact (7), the or each cavity being open along two intersecting sides (9,10) of the housing so as to receive the mating electrical contact in the cavity and also having an opening along a third side (23) through which the contact (4) is inserted into the cavity upon assembly, the or each contact having a cantilever contact portion (15) which extends diagonally and forwardly within the cavity towards the two open intersecting sides and which has a tip (17) received in a channel (24) in the cavity, wherein the or each cavity (3) comprises first and second cavity portions (5,6), the associated contact (4) is disposed in the first cavity portion (5) with its contact portion (15) extending into the second cavity portion (6), and the channel (24) receiving the tip (17) of the contact portion extends forwardly in the first cavity portion (5) from the opening in the third side (23). An electrical connector as claimed in claim 1, wherein the or each electrical contact (4) comprises a blade (11) having its contact portion (15) extending diagonally therefrom, said blade being mounted in the associated first cavity portion (5). An electrical connector as claimed in claim 2, wherein the blade is mounted in the associated first cavity portion with opposite edges engaged in the channel (24) and an opposed channel (25) of the first cavity portion (5) also extending forwardly from the opening in the third side (23) of the housing (2). An electrical connector as claimed in claim 1, 2 or 3, wherein the first cavity portion (5) of the or each cavity (3) extends forwardly from the opening in the third side (23), and the second cavity portion (6) is open along the two intersecting sides (9,10) for receiving the mating electrical contact into the second cavity portion.

Inventors: DAVIS WAYNE SAMUEL, DAVIS, WAYNE SAMUEL
Applicants: WHITAKER CORP, THE WHITAKER CORPORATION
Application year: 1994
Main classification: H01R23
IPC codes: H01R13, H01R12, H01R24, H01R31